Liquid peroxidic compositions

ABSTRACT

The invention relates to liquid peroxidic compositions containing: 
     from 1 to 50 parts by weight of a diperoxide of formula: ##STR1## from 5 to 75 parts by weight of dicumyl peroxide; from 1 to 85 parts by weight of a peroxide of formula: ##STR2##  wherein R is H or an alkyl group containing from 1 to 3 C atoms and wherein A is selected from the radical CH 3  and the phenyl radical, optionally substituted.

BACKGROUND OF THE INVENTION

Italian Pat. No. 1,114,215 describes liquid peroxidic compositions,particularly useful for the cross-linking of polymers (for instancepolyethylene or ethylene-propylene elastomers) containing dicumylperoxide (indicated hereinbelow, for sake of brevity, DCP), a peroxidethe use of which (alone) is limited in that, being DCP a solid at roomtemperature, it is necessary that DCP itself, with the purpose of a moreuniform metering (in a continuous operation) be kept in the moltenstate; such operation often involves a loss of the peroxidic activityand the introduction of impurities. Therefore, the above mentionedItalian Patent suggests the use of balanced peroxy-mixtures, containingan amount of DCP from 5 to 75% together with peroxides which give riseto the formation of liquid mixtures and are comprised in the followinggeneral formula (I) ##STR3## wherein R, in meta or para position, is analkyl group containing from 1 to 3 C atoms. In particular, peroxideswhere R represents a methyl group are recommended, whereas according toU.S. Pat. No. 4,202,790, it is more advantageous the use of a peroxidewhere R is an isopropyl group, namely the use of isopropylcumyl-cumylperoxide, provided the percentage of DCP in the peroxidic mixture beequal to or higher than 25% and preferably 40% by weight. Said U.S.patent advises to prepare the mentioned peroxides separately (and attemperatures above the room temperature) and thereafter to mix the thusobtained peroxides with DCP, according to the desired ratios.

The Applicant has now found that some particular peroxidic mixtures,different from the mixtures described by said U.S. Patent, give rise tobetter results, in comparison with the preceding mixtures, and can beprepared and treated in a much simpler and more practical way.

DISCLOSURE OF THE INVENTION

In its widest form the invention is concerning a liquid peroxidiccompositions, containing: from 1 to 50 parts by weight of a diperoxideof formula (II): ##STR4## the two substituting groups of the centralaromatic ring being in meta and/or para position and the meta/paraisomeric ratio being from 1.2 to 2.5 and better from 1.5 to 2.1; thisperoxide is commercially known as "PEROXIMON 169";

from 5 to 75 parts by weight of dicumyl-peroxide (DCP);

from 1 to 85 parts by weight of a peroxide having formula (III):##STR5## where R is H or a 1-3 Calkyl group, and A is selected from theradical CH₃, the phenyl radical and the substituted phenyl radicals.When R is H, A should represent preferably the radical CH₃ and when R isthe isopropyl radical, A should be preferably selected from the radicalCH₃ and the phenyl radical; the group R can be in meta and/or paraposition, the meta:para isometric ratio being preferably in the rangefrom 1.2 to 2.5 and better from 1.5 to 2.1.

Said peroxide of formula (II) was already described in U.S. Pat. Nos.3,787,504 and 3,118,866, the content of which is an integrating part ofthe present application. The new compositions differ from DCP in thatthey are liquid at room temperature and therefore can be incorporatedinto a polymer without any previous melting; furthermore, they can beeasily proportioned and the mixing operation can be performed in a verysafe manner. Very uniformly finished articles can be thus very easilyobtained.

Unlike the previously known products of formula (I), the diperoxide offormula (II) owns a cross-linking power (on polyethylene) higher thanthat of DCP and therefore it is not necessary to increase the amount, asin the case of mixtures containing DCP and peroxides of type (I); theincrease of the amount, as to liquid mixtures, containing DCP andperoxides of type (I) is generally between 20 and 35% by weight.

The compositions according to the invention are liquid and therefore itis possible to avoid more easily the presence of impurities; in fact, itis easier, in our case, to detect and remove extraneous substances ifincorporated.

The cross-linking efficiency of the new compositions may be comparedwith that which can be obtained using pure DCP and as the mixing ofliquid compositions with a polymer (in an extruder) does occur veryeasily, the working of the polymer is simplified. The polymers which canbe cross-linked by the new compositions are generally olefin and vinylthermoplastic polymers, as well as elastomeric polymers. Moreparticularly, it is possible to mention: middle, low and high densitypolyethylene, poly-butene-1, ethylene/vinylacetate copolymers, acrylicester-ethylene copolymers, ethylene/propylene copolymers,ethylene/butene-1 copolymers, ethylene/4-methylpentene-1 copolymers andpropylene/butene-1 copolymers; furthermore, we add elastomeric polymersor copolymers such as for instance ethylene/propylene copolymers of thetype EP or EPDM, butyl rubber, chlorinated polyethylene and thepropylene/butene-1 copolymer.

Also mixtures of at least two olefinic thermoplastic polymers, mixturesof at least two polymers of elastomeric type and mixtures of at leastone olefinic thermoplastic polymer with at least an elastomeric polymercan be successfully cross-linked. The new compositions can be used notonly for the cross-linking of compact articles, obtained by extrusion ormolding, but also for producing expanded cross-linked articles derivedfrom the same materials, in particular from polystyrene containingself-extinguishing agents (antiflame agents); moreover, the samecompositions can be used to promote the decomposition of polymers whichare decomposed by peroxides (for instance polypropylene orpoly-4-methyl-pentene-1) and as a radical polymerization initiator.

The processes which may lead to the compositions according to theinvention are different. According to a preferred embodiment, benzene isalkylated with an excess of propylene, in the presence of AlCl₃ andaccording to generally used techniques such as Friedel-Crafts reaction,thus obtaining a di-isopropylbenzenic mixture (prevailingly meta andpara); this mixture is oxidized, always by generally used techniques,until a prefixed amount of dihydroperoxide, corresponding to the desiredtitre of diperoxide of formula (II) is obtained, besides themono-hydroxide. The resulting oxidized mixture, containing unreactedhydrocarbons, as well as the corresponding monohydroperoxides anddihydroperoxides, is then reduced, for instance by sulfides, sulfites orsulfohydroxides (according to generally used techniques), so that allthe hydroperoxy groups are changed to alcoholic groups (hydroxy groups)and the obtained reduced mixture is uncompletely distilled; a rectifiedmixture is thus obtained, containing a mono-alcohol having formula (VI):##STR6## and up to 30% by weight of a di-alcohol having formula (IV):##STR7## together with lower amounts (up to 15%) of unconvertedhydrocarbons. Depending on the composition of the desired peroxidicmixture, there are then added, in some cases, amounts of particularalcohols (equal to or different from the preceding ones), in particularcumyl alcohol of formula (V) (see forward).

The mixture containing the alcohols, anyhow prepared is then allowed toreact with a cumene mixture (deriving, for instance, from theintermediate step of an usual plant for the synthesis of phenol),containing higher amounts of cumene hydroperoxide and up to 10% byweight (on the hydroperoxide) of cumyl alcohol having formula (V):##STR8## (common component of generally handled cumenic mixtures) in thepresence of one of the commonly used acid catalysts described in U.S.Pat. Nos. 4,266,081; 4,239,644; 4,202,790; and 2,668,180, which supplyalso the operative conditions; paratoluensulfonic acid, especially whengradually added in one single dose or in portions, has provedparticularly effective also at relatively low temperatures (lower than40° C.).

Before using the resulting peroxidic mixture, it must be carefullywashed, for instance with an alkali metal solution; it is important thatthe reaction synthesis be performed under an inert atmosphere, forinstance under nitrogen. The washed peroxidic mixture must beconcentrated, thus removing any compound having low boiling temperature(essentially diisopropylbenzene and cumene), preferably by steamdistillation. In some cases, it is possible to add a peroxide of formula(III) directly to the peroxidic mixture obtained following the abovementioned operations. The following examples illustrate the invention,without limiting it in any way.

EXAMPLE 1

A rather great amount of benzene was alkylated with two mols ofpropylene, in the presence of AlCl₃ and according to usualFriedel-Crafts techniques, thus obtaining a mixture ofdiisopropylbenzenes; this mixture was then oxidized, always by generallyused techniques, thus obtaining an oxidized mixture (containingpara-di-isopropylbenzene, meta-diisopropylbenzene,para-di-isopropylbenzene mono-hydroperoxide, para-di-isopropylbenzenedihydroperoxide, metal-diisopropylbenzene monohydroperoxide andmeta-di-isopropylbenzene di-hydroperoxide). Said oxidized mixture wasthen reduced with sodium hydrosulfide (NaHS), according to usualtechniques, so that all the hydroperoxy groups (--O--O--H) wereconverted into alcoholic groups (hydroxy groups). Thereafter theresulting reduced mixture was distilled off; a rectified mixture wasthus obtained containing 84.8% by weight of a mixture of isopropyl-cumylmonoalcohols (35% of para+65% of meta) and 4.7% by weight ofisopropyl-cumyl di-alcohols (35% para+65% meta).

133 g of said rectified mixture were loaded into a glass round-bottomedflask provided with stirrer, thermometer and vacuum tap; thereafter,171.7 g of a cumene mixture containing 78.5% by weight of cumenehydroperoxide, 7% by weight of cumyl alcohol (V) and 10% by weight ofnonoxidized cumene were added; there were present:

(a) 0.632 mol of mono-alcohol + 0.032 mols of di-alcohol;

(b) 0.886 mol of cumene hydroperoxide + 0.088 mol of cumyl alcohol.

Thereafter, 71 g of an aqueous solution containing 70% by weight ofpara-toluensulfonic acid were added, gradually, within 30 minutes, at25°-28° C. under nitrogen and the mixture was allowed to react, at25°-28° C., for 3.5 hrs, under stirring. After the end of the reaction,the acidic aqueous phase was separated in a separatory funnel and 2washings were carried out, using each time 200 cm³ (at 60° C.) of anaqueous 10% by weight NaOH solution, followed by other two washings,using each time (at 60° C.), 200 cm³ of deionized water. After havingremoved the cumene, by steam distillation, and after having dehydratedunder vacuum at 65° C., the resulting peroxidic mixture contained anoxygen amount corresponding to 4.7% by weight and showed a purity degreeequal to 91% by weight (total peroxydic content), a density of 0.098g/cm³ and a viscosity (at 25° C.) equal to 126 mPa.s. Half life valuesof the mixture (thermal decomposition) were 113° C. (after 10 hours) and188° C. (after 1 minute); the analysis showed that the mixturecontained:

    ______________________________________                                         di (cumylperoxy)-diisopropylbenzene                                                                    4% by weight                                        (meta/para) (PEROXIMON 169)                                                   dicumyl-peroxide (DCP)   13% by weight                                        isopropylcumyl-cumyl peroxide (meta/para)                                                              73% by weight                                        ______________________________________                                    

The remaining 10% was consisting of hydrocarbons and/or unreactedalcohols. Isopropylcumyl-cumylperoxide is known on the marked asPEROXIMON 168.

EXAMPLE 1/a

100 parts by weight of an ethylene-propylene elastomeric copolymer,known by the trade name DUTRAL COO 54, were mixed with 0.3 parts byweight of sulfur, 5 parts by weight of ZnO and 50 parts by weight ofcarbon black. To the mix there were added 3.46 parts by weight of theperoxidic mixture of example 1 and the resulting blend was homogenizedin a calender; the product obtained from the calender had the followingproperties:

(a) data of the ODR curve at 170° C. (oscillation arc=3°; oscillationfrequency=100 cycles/minute; see FIG. 1);

MH=82.6 inch pounds

t_(s10) =102 seconds

t₉₀ =456seconds

A ODR curve (Oscillating Disc Rheometer) has a course (flow) of the typeindicated in FIG. 1 and is plotted by the aid of a rotating discrheometer, according to ASTMD-2084-71T standards.

On the abscissa there are reported times and on the ordinate thetwisting torque (inch pounds, measured by means of a dynamometer)opposed by the polymer to the rotation of the disc; in our case thehighest cross-link density is revealed by the highest value of thetorque (MH=82.6 inch pounds) which does no more vary with the time.Expressions t₉₀ and t_(s10) respectively represent the time necessary toreach a twisting moment equal to 90% of the highest twisting moment andthe time necessary to reach a level of 10 inch pounds above the lowestpoint of the ODR curve.

As to other details we refer to U.S. Pat. No. 4,015,058

(b) "scorching" times at the Mooney viscosimeter (at 135° C.):

ts₁₀ =738 seconds

ts₁₅ =900 seconds

As "scorching" we mean the untimely vulcanization which takes place(undesirably) during the extrusion of the blend, before its outlet fromthe die; this premature vulcanization its often causing a shut down ofthe operations.

As scorching time ts₁₀ or ts₁₅ (at the Mooney viscosimeter) we mean thetime necessary to reach an increasing of the lowest value of theviscosity equal to 10 to 15 Mooney units respectively. The viscositymust be determined by means of a cutting disc Mooney viscosimeter (seeASTM D 1646-81 Standards).

EXAMPLE 2

18.8 g of the rectified alcohol of Example 1 were loaded into the sameglass round-bottom flask, provided with stirrer, together with 74 g of amixture containing 85% of cumyl alcohol and 10% of cumene (obtained byreducing 78% commercial cumene hydroperoxide); thereafter 36 g ofdialcohol of the diisopropylbenzene (solid; 65% meta+35% para) andfinally 205 g of 78.5% by weight of commercial cumene, containing 7% byweight of cumyl alcohol and 10% by weight of cumene were added. On thewhole were present:

0.09 mol of m/p-diisopropylbenzene monoalcohol;

0.19 mol of the m/p-diisopropylbenzene dialcohol;

0.568 mol of cumyl alcohol;

0.233 mol of cumene;

1.059 mol of cumene hydroperoxide

Thereafter 71 g of a 70% b.w. aqueous solution of para-toluensulfonicacid were added within 30 minutes; then the mixture was allowed to reactfor 3 hours, the temperature being adjusted between 25° C. and 28° C. Byfurther working as in Example 1, 210 g of a liquid product wereobtained, having the following composition:

alpha, alpha'-bis (cumylperoxy)diisopropylbenzene (PEROXIMON 169)=33% byweight

dicumylperoxide (DCP)=57% by weight

isopropylcumyl-cumylperoxide (PEROXIMON 168)=103% by weight

This product had an active O₂ content equal to 6.1% a freezing pointlower than -5° C. and a viscosity at 20° C.=50 mPas; half life values ofthe mixture (thermal decomposition) were 116° C. (at 10 hours) and 179°C. (at 1 minute).

EXAMPLE 2/a

100 parts by weight of a polyethylene blend, suitable for cableinsulation, manufactured by B. P. Chemicals Co. and known by the tradename HF NM 4993, were admixed with 2.5 parts by weight of the peroxidicmixture of Example 2 and the resulting mixture was homogenized in acalender; the product coming out from the calender was molded bycompression and tested at the ODR rheometer at 180° C. (oscillationarc=5°) thus obtaining the following results:

MH=78 inch pounds;

t_(s2) =66 seconds; t₉₀ =288 seconds.

Analogously to what described in example 1, t_(s2) indicates the timenecessary to reach a level of 2 inch pounds above the lowest point ofthe ODR curve.

EXAMPLE 3

250 g of a mixture containing 57% by weight of cumene hydroperoxide, 30%by weight of cumyl alcohol and 10% by weight of cumene, obtained bypartial reduction of commercial cumene hydroperoxide (78.5% by weight)were loaded into a round-bottom flask provided with stirrer; thereafter37 g of a meta/para mixture (65% meta+35% para) of diisopropylbenzenedialcohol were introduced. On the whole 0.94 mol of cumenehydroperoxide, 0.55 mol of cumyl alcohol and 0.19 mol of meta/paradiisopropylbenzene di-alcohol were present. Then, 71 g of a 70% byweight aqueous solution of para-toluensulfonic acid were introducedwithin 30 minutes and under stirring, while keeping the reactiontemperature between 25° and 30° C.; the mixture was allowed to react atthis temperature for 3 hours. By working as in Examples 1 and 2, 190 gof a product (liquid at room temperature), containing 60% by weight ofdicumyl peroxide and 35% of di(cumylperoxy)diisopropylbenzene wereobtained; 21 g of tert.butylperoxide were added. At the end a productwas obtained, containing 32% by weight ofdi(cumylperoxy)diisopropylbenzene (PEROXIMON 169), 54% by weight ofdicumylperoxide (DCP) and 10% by weight of tert.butyl-cumylperoxide;this final liquid composition showed the following characteristics:

freezing point: lower than -5° C.;

viscosity at 20° C.: 45 mPas;

active oxygen content: 6.2% by weight.

Half life times were 117° C. (at 10 hours) and 181° C. (at 1 minute).Tert.-butyl-cumylperoxide is commercially known as "PEROXIMON 166".

EXAMPLE 3/a

100 parts by weight of the polyethylene blend of Example 2/a wereadmixed with 2.5 parts by weight of the peroxidic mixture of example 3and the resulting blend was homogenized in a calender; by working as inExample 2/a the following results were obtained:

MH=85 inch-pounds

t_(s2) =54 seconds; t₉₀ =300 seconds.

Analogously to what described in U.S. Pat. No. 4,015,058, the content ofwhich is integrating part of the present application, the quality of aperoxidic composition can be easily evaluated by calculating anefficiency factor (E) according to the equation:

    E=(MH.t.sub.s2):(t.sub.90 -t.sub.s2)

The following table reports the efficiency factors obtained in theexamples:

    ______________________________________                                        COMPOSITION OF THE PEROXIDIC                                                  MIXTURE                                                                             PEROX-            PEROX-  PEROX-  E =                                         IMON              IMON    IMON    MH. t.sub.s2                          Ex    169       DCP     168     166     t.sub.90 -t.sub.s2                    ______________________________________                                        2/a   33%       57%     10%     --      23,19                                 3/a   33%       57%     --      10%     18,65                                 4      2%       57%     41%     --      13,25                                 ______________________________________                                    

In Examples 2/a and 3/a the presence of PEROXIMON 169, on which theinvention is based, gives an efficiency much higher in comparison withExample 4 where the diperoxide is almost completely replaced by amonoperoxide (PEROXIMON 168).

EXAMPLE 4

Example 3/a was repeated by replacing almost all the diperoxide orformula (III), according to the invention, by a comparable amount ofPEROXIMON 168, thus obtaining the following results:

MH=50 inch pounds;

t_(s2) =66 seconds; t₉₀ =315 seconds.

What we claim is:
 1. Liquid peroxidic compositions containing:from 1 to50 parts by weight of a diperoxide of the formula (II): ##STR9## the twosubstituting groups of the central aromatic ring being in meta and/orpara position and the meta/para isomeric ratio being between 1.2 and2.5; from 5 to 75 parts by weight of dicumyl-peroxide; from 1 to 85parts by weight of a peroxide of the formula ##STR10## wherein R is H oran alkyl group containing from 1 to 3 C atoms, and wherein A is selectedfrom the radical CH₃ and the phenyl radical.
 2. Compositions accordingto claim 1, containing from 50 to 70 parts by weight ofdicumyl-peroxide.
 3. Compositions according to claim 1 or 2, wherein themeta/para isomeric ratio, for the peroxide of formula (III) is from 1.2to 2.5.
 4. Compositions according to claim 1, wherein the meta/paraisomeric ratio, for the diperoxide of the formula (II), is from 1.2 to2.5.
 5. Compositions according to claim 1, containing:from 20 to 45parts by weight of diperoxide of formula (II), wherein the meta/paraisomeric ratio is from 1.2 to 2.5; from 50 to 70 parts by weight ofdicumyl-peroxide; from 1 to 25 parts by weight of a peroxide of theformula: ##STR11##
 6. Compositions according to claim 1, containing:from20 to 45 parts by weight of diperoxide of formula (II), from 50 to 70parts by weight of dicumylperoxide; from 1 to 25 parts by weight of aperoxide of the formula; ##STR12##
 7. A process for the manufacture of acomposition according to claim 1, comprising:(a) the oxidation of meta-and/or para-diisopropyl-benzene, by which oxidation an oxidized mixtureis formed, containing a major amount of isopropylcumylmono-hydroperoxide and up to 12% by weight (on the mono-derivative) ofthe corresponding di-hydroperoxide; (b) the reduction of said oxidizedmixture, by which reduction a reduced mixture is formed, wherein thehydroxyl groups (alcoholic groups) replace the hydroperoxidic groups ofsaid oxidized mixture; (c) an optional distillation of said reducedmixture, to obtain a concentrated mixture, containing a major amount ofisopropylcumyl mono-alcohol and up to 30% by weight of the correspondingdi-alcohol (optionally dissolved in the starting hydrocarbon); (d) anoptional admixture with additional amounts of cumyl alcohol and/orm/p-diisopropylbenzene dialcohol, so that the amounts ofdicumyl-peroxide and/or of the diperoxide of formula (II) in the finalliquid peroxidic compositions are increased; and (e) the reaction with acumenic mixture, containing a major amount of cumene hydroperoxide andup to 10% by weight (on the hydroperoxide) of cumyl alcohol.
 8. Aprocess according to claim 7, wherein the reaction under (e) isperformed in the presence of para-toluensulfonic acid, at a temperatureequal to or lower than 40° C.
 9. A liquid peroxidic compositionaccording to claim 1, wherein the meta/para isomeric ratio is between1.5 and 2.5.
 10. A liquid peroxidic composition according to claim 3,wherein the meta/para isomeric ratio for the peroxide of formula (III)is from 1.5 to 2.1.
 11. A liquid peroxidic composition according toclaim 4, wherein the meta/para isomeric ratio for the diperoxide offormula (II) is from 1.5 to 2.1.